nesta Soren en Apes ed Stress state in the saddle zone of pressure vessels and piping Shen Naijie* Zhejiang Univer of Technology, People's Republic of China Zhu Jitao Mangchou Orygen-Produetion Machinery Plant, People's Republic of China & Lu Wenge Zhejiang Provincil Patent Administrative Ofc, People's Republic of China (Received 20 May 1998: accepted 20 June 1984) To investigate the stress tte inthe saddle 20ne of presure vessels ad piping 4 Simple mechanical model convenient for both experimental and these fnales has been designed. Eleicalsirtn pave messorements have been taken on the model ands double Fourerseres expansion method is used to tnalyze the model. To determine the contac pressure dstibution pattern between saddle and model tube, 4 thal and etror method proposed by authors 1 INTRODUCTION Most of the present design codes dealing with saddle supported pressure vessels are based on the semi-empirical analysis method proposed by Zick in 1951." Saddle supports are used not only in pressure vessels, but also in piping, Usually, the design method adopted in pressure vessels is, also used in designing piping supports. In all such designs the stress state in the saddle zone is followed with interest by designers, The determination of the stress state in the saddle zone depends on many factors, such as contact pressure distribution pattern and the stress analysis. method. However, engineering practice shows that Zick's design method sometimes is not sufficient to describe all these practial factors. With the development of the computer there ‘To whom correspondence showld be addressed at Department of Mechanical Engineering Zhejiang Univer ity of Technology, Hangzhou, Zhejiang 310018, Chiaa has been a lot of work on the structural analysis method and experiment technology, including the prediction of contact pressure distribution by finite element mixed method, the solving of the local loaded shell structure by the double Fourier series expansion method and the measuring of experimental stresses by the strain gauge method, which have been done to improve the Zick’S design method. In this paper, a simple mechanical model convenient for both experiment and theory is proposed. It is applied to a segment of a thin-walled aluminium-alloy tube (Fig. 1). Two rigid ring plates were welded to two edges of the tube at the points of the simple supports during experiment. A saddle is inversely placed in the middle of the tube. The stress state in the saddle zone was investigated by a method which ned the results with theory. The present ‘method consists of three stages: (1) Placing the model into a universal test ‘machine, loading the model by means ofShen Nate, Zhu Ftao, Lae Wenge Fig. L The experimental model test machine and saddle, and then making electrical resistance strain gauge measure ‘ment in the saddle zone. Analyses of the model structure by means fof the double Fourier series expansion method. (3) In the double Fourier series expansion method it is necessary to know the contact-pressure distribution pattern bet ween saddle and tube. However, the various contact-pressure distribution pat- terns proposed in the past were sometimes inconsistent with the actual situation in engineering problems. To determine the contact-pressure distribution pattern of a real structure, a tial-error_ method is specially proposed in this paper. Q 2 EXPERIMENTAL MODEL AND ELECTRICAL RESISTANCE STRAIN GAUGES 2.1 Experimental model The experimental model was a segment of thin-walled aluminium-alloy tube as shown in Fig. 1. The results from two tubes with different ‘Table 1. Geometric Tube Material Elastic Posson’s umber modulus Erato. ¥ (GPs) Te LRT oat Tue? LED n bat materials and different radius-thickness ratios are given in this paper. The two tubes are ‘numbered as Tube 1 and Tube 2. Their geometric and material parameters are listed in Table 1 ‘Two rigid ring plates were welded 10 two edges of each tube at the points of the simple supports during experiment. The ring plates are 10mm in thickness and were used to prevent excessive local deformation possibly produced at two edges. ‘A saddle made of aluminium plate was inversely placed in the middle of the tube. Details of this are: saddle angle, 2B = 120". saddle width, 2c = 30mm, and circular are radius of the saddle, R= 105 mm, 2.2 Electrical resistance strain gauges It is known that the most critical stress values ‘occur in the circumferential and longitudinal directions. Thus, cross strain gauges are adopted. located in these directions and fixed to the outside surfaces of the tubes. 23 Gauge arrangement ‘The arrangement of the gauges for Tube 1 is shown in Fig. 2. Gauges No. 13, 14, 15 and 16 are id material parameters of Tube 1 and Tube 2 soa. ‘Thickness.¢ Span. L_ External (st) "amy “fmm radius, om) o 4 110 a i 5 110sStress stare in the saddle zone of pressure vessels and piping 197 Fig, 2 Gauge arrangement for Tube 1 used to inspect the symmetry of measuring values 3 DOUBLE FOURIER EXPANSION, relative to X = L/2 Gauges No. 87,8, 89,90,91 METHOD. find 92 are used to inspect the symmetry” of measuring values relative to @ = 0 oe ‘ “The arrangement of gauges for Tube 2 is %4 Governing differential equation and Fourier shown in Fig. 3. Gauges No. 47,48, 49 and 50 are ©*Pamsion tsed to inspect the symmetry of measuring values relative to X = L/2, Gauges No. 51, 52,53 and $4 To analyze the thin-walled tube loaded by saddle fare used to inspect the symmetry of measuring pressure as shown in Fig. 1, i is assumed that a ‘alu relative tg =C- linear elastic small displacement situation exist. Fig. 8 Gauge arrangement for Tube 2.18 Shen Naijie, Zhu Jtao, Lu Wenge Therefore, the behaviour of the tube can be described by a set of differential equations using au ae ag? aw agi 8 The positive directions of the mid-surface displacements 1, v and w and the surface loading ‘components p,, py and p, are given in Fig. 4. The first step to solve eqn (I) using the double Fourier expansion method is to represent all the known and unknown functions by double Fourier series. Double Fourier series expansions for mid-surface displacements and loading com- ponents can be expressed as: Fig 4. Coordinates and symbol rl a ky Badd 49) 3401 = IR a+) 3k IRs +k) ia ‘mid-surface displacements and surface loading ‘components as follows?” Py ar ae av rae ew © ag (Wine 608.19 + Wu Sin ng )sin(mex/L) (uns cos ng + uz sin ng)eos(mnx/L) (inosine ~ vin cosne)sin(mmc/L) | (oy (Pins C08g + Pine Sin ng)sin(mze/ L) (pomcosmng + pins sin ng}oos(mnxx/L) (Pom 5.18 ~ Pam C08 ng)sin(mxX/L) in which coefficients without a prime correspond to symmetric loading form relative to ¢ =0" and coefficients with a prime correspond to. anti- symmetric loading form. This measure enables us to deseribe both symmetric and antisymmetric functions. The origin of the coordinates system is take at the left end of the tube. Therefore, all the Fourier expansions or their derivatives containing the term sin(max/L) vanish at two edges of the tube. This implies that the provided, simply: supported boundary conditions have the follow- ing features: two edges of the tube may not deform in its cross section, may not have rigid displacement or rotation, and may not bear longitudinal load. ‘The boundary conditions mentioned above do not completely describe the actual situation of two edges: however, itis accurate enough for the case that loading points are far away from the edges. ‘The second step is to divide the displacement and load functions into two parts: the symmetric and the anti-symmetric parts. Then, by substitut- ing each part separately into eqn (I), displace: ‘ment expressions, in which only the displacement and loading coefficients are involved, can be obtained. Displacement coefficients of symmetric and anti-symmetric parts can be expressed inSiress state in the saddle zone of pressure vessels and piping 159 matrix form as follows Fim fe» Ehime in which [K] is the stiffness matrix. Note that there is a minus before tn and Por in eqn (2). so the stiffness matrix in eqns (3) and (4) are just the same. The elements of [K] can be obtained by substituting eqns (2) into eqn (1), and its results are: Kyat kQe ex) Ka = ALM ~ vk? — vy] = Kay Ky =n (1 + 1k) +18 — kd? = Ky MO W904 + kn Kay=—Inala(1 + v) —3k(1- 9) Ky = (1+ 6) + 11 ~ 9)(4+ 9K)A in which A=maR/L. After having the displace- ‘ment coefficients, itis obvious that the following analyses can be performed. Suppose [Z] = {K] '. Because [K] is a symme ric matrix, so [Z] is also a symmetric matt Substituting eqns (3) and (4) into eqn (2), double Fourier series expansions for displacements can be obtained as follows: “335 6) Zl Pn 05 E + Pen Sin ne )eos(rnacx L) Zs Py SiN. NG ~ Png COS NG)Sin(ma/L) 6 in which j=1, 2, 3 are related separately to radial, longitudinal and circumferential directions. By using strain-displacement relations, double Fourier series expansions for strain and curvature can then be obtained as follows: fi (Pron £088 * Pi soccer x ky ko RLF, R(nZy + ZF, Lease Riaz, nd) 7 PP» ananniel o 2 af zy (WZ, + nZy)F GAZ, HAZ, + ZF in which F, = (Pan COSNG + Pin Sin ng)sin (rmx) L) and F= (Pym SG ~ Pe SOSH JCOS(M AL) Once eqn (7) is obtained, the double Fourier series expansions for stress resultants can be ‘obtained by using stress resultant~displacement relations: [-ZaRA + vR(Zan +2) R(Zyn+ Zy)B + VARZaFe fe Hr wpa ZORA ~ Zak > Dass myZuh ‘) xf Boerne “6 Dayeen® ae YZuF, pa A ) AZ Bs After stress resultants are obtained, using relations between stresses and stress resultants; 0) the stresses on inner and outer surfaces of the tube can be determined.160 ‘Shen Naije, Zhu Jtao, Las Wenge 32 Determination of loading coefficients In the above derivations, only the loading coefficients py and py are unknowns. For some typical loading types, these loading. coeticients can be determined by multiplying both sides of the loading terms contained in eqn (2) by suitable orthogonal functions such thet integration over the surface of the tube eliminates all but one of the terms in each Fourier expansion. By this procedure, the expressions for loading Coeiciens Pon ANd Pi aFe obtained a8 follows for radial loading zt f |, P cos ng sin(mmx/L) dx dp ( Bf [pscemesinomat) tae 223,202) (oy (mm=1,23.000) oA 2. [o-sonesninst (nm =1,2,3, ) ay for longitudinal loading ef [nase m=0m=0 isl Preto ul sae 22,3,..sm=0) (12) el epeeecuas (1m=1,2,3.0.0) Ef [nanneseas a 2 fp snnecomelt) ade (m, n= 1.2.3.0.) for circumferential loading A [psonesoomsrt avd (mn=1,2,3...) (14) Ff [pe sinonnx/t) ax de on in=0) 2 [pe cosnesinonnstt) ax ae (mn =1,2,3,..) By using eqns (10)~(15), most types of loadings ‘can be readily expressed as double Fourier series. 3.3 Computer program DFEM and its applications For the whole procedure of the double Fourier expansion method described above a computer program named DFEM has been developed. Some typical types of local patch loadings (as ‘shown in Fig. 5) or line loadings and any of their combinations, can be directly treated by this program (DFEM). Loading types other than those shown in Fig. 5 may be considered as a combination of different loading types shown in Fig. 5 By this route, based on eqns (10)-(15) and using program DFEM, most actual loadings can be conveniently expressed as double Fourier series. Fig 5 Throe types of patch lings acting on the surface ‘of elindsieal sell,Siress sate inthe saddle zone of pressure vessels and piping 161 4A TRIAL-ERROR METHOD TO PREDICT CONTACT-PRESSURE DISTRIBUTION PATTERN Assumptions for contact-pressure distribution pattern In the double Fourier series expansion method it is_necessary to know the contact-pressure distribution pattern between saddle and tube. However, the various contact-pressure distribu- tion patterns proposed in the past were sometimes inconsistent with the actual situation in engineering. Contact-pressure distribution patterns may be affected by many factors, especially by contact stiffness between saddle and. tube. To determine the contact-pressure distribu- tion pattern of a real structure, a trial-error ‘method is proposed here. For most engineering problems, it is reason- able to assume that the contact pressure is in a radial direction and of uniform distribution along the width of the saddle. According to different contact stifinesses, three typical types of comtact- pressure distribution patterns are assumed as follows: (1) When saddle stitnes is much greater than tube stfess (Fi. 6(2)) y __P [=£08 6 ~ 00s B to) sl anenB in which 2c is the saddle width. Equation (16a) was proposed by Zick” and based on strain” gauge’ experiments for saddle- Sipported vessels. 63 (2) when saddle stiffness is close to tube stiffness (Fig. 6(6)) Plg= a) in B + 2B cos B — 2sin B) (166) (3) when saddle stiffness is much less. than tube stiffness (Fig. 6(c)) Pp 4eR sin B Pe) (166) Generally, for real engineering structure, contact pressure varies with contact stiffness and. other factors. However, it may be simulated by combining the above” three typical contact- pressure distribution patterns Po) = KiR(@)+ KA) + KsPCOY) K+K.+Ky1 an in which P'(g) is the simulated contact-pressure distribution pattern and Ky, K; and K, are weight factors. By selecting different Ky, Kz and Ky, a series of different contact-pressure distributions ‘may be obtained. 42 Trial-error method When a real saddle supported tube is analysed, three steps must be taken in the trial-error method: (2) Selecting any set of K,, K: and Ky (note that Ky+K.*K,= 1), an initial trial ig. 6, Contuct-pressue dstebation pattern assumptions,162 ‘Shen Naije, Zhu Jiao, Lu Wenge ig. 7. Contact pressure distribution pater. contact-pressure distribution can be ob- tained from eqn (17). With this distribu tion, the tube can be analysed by program DFEM and the theoretical stress. status ‘obtained. (2) A small amount of electrical resistance strain gauge measurements must be done at some characteristic points on the surface of the tube and experimental stresses at these points obtained. Adjustment is required of K,, Kz and K; 10 minimise the mean square deviation between theoretical and experimental str: cesses for the above characteristic points. This step can also be done automatically by computer program DFEM. Using the final values of Ky, K: and K,, the whole tube can be analysed finaly. Q For the proposed mechanical model shown in Fig. 1, the obtained contact-pressure distribution using the trial-error method is shown in Fig. 7. 5 COMPARISON OF EXPERIMENTAL AND THEORETICAL CALCULATION OF RESULTS. Electrical resistance strain gauge measurements for the whole tube were taken on the test ‘machine during loading, For Tube 1 it was found that a larger deformation is produced in the loading zone; the tube tends towards cave-in when the load reaches a certain level. With a progressive increase of the load, cave-in of the tube will occur in loading zone. The limit load of plastic cave-in was found to P= 16-40 kN, When P = 5-20KN, the circum ferential stresses at points (550,110) and (540,110), namely at the position of gauges No. 32 and No. 34, have arrived at yield stress. This ‘means that for Tube 1 the load at which the initial yield point occurred is Py = 20KN. For Tube 2, the experimental phenomenon was basically consistent with Tube 1 except that the limit load of plastic cave-in was P, = 78-4 kN. For brevity, only the results for Tube 2 are given below. The stress-distributions on the outer surface of Tube 2 are shown in Figs 8 and 9. All of the experimental stresses under different loadings are reduced proportionally by convert- ing the loadings into P,=2kN and then marking fon the same figure (P, is the load density under uniform contact-pressure-distribution —assump- tion). The contact aspects between saddle and lube are expressed in Table 2. ‘Theoretical stress curves are also given in Fig. 8 and 9. Here, the so called theoretical calculation means that the saddle-supported thin-walled aluminium tube, shown in Fig. 1, is considered as a thin-walled cylindrical shell under local loading at saddle and then the basic governing-differential equations of thin shells are solved by the double Fourier expansion method. ‘The calculations are completed by the computer program DFEM, developed by the authors. Obviously, the results of the calculations are related t0 the assumption of contact-pressure- distribution-pattern between saddle and tube. Zick’s* distribution assumption (Fig. 6(a)) and Bijlaard’s* uniform distribution assumption (Fig. 6(c)) are used separately by the authors. Table 2. Contact aspects between saddle and tube Number External Saddle contact Pad between radius. ®, radius sade ad (eam) ‘am) tube Tabet 108 10S 2mm in thickness aed rubber Tube 2105 us ‘vthoutSirese state inthe saddle zone of pressure vessels and piping 163 7 20 w 1 1 " or se 3 Pa 2 5 0 5 ao i ; 3 (D asthrs Bias, ky Fig. 8 Longitudinal streses of Tube 2. Caleulation results show that the theoretical stress curves (marked separately with ® and @ in Figs 8 and 9) coincide very well with the experimental results for a large portion of the tube that is farther away from the loading zone: however, in the vicinity of the saddle zone, a larger difference exists between the two. The reason for this lies in the larger discrepancy existing between the assumed contact-pressure distribution patterns and its actual conditions. For this reason the trial-error method mentioned in Section 4 is used to form a contact-pressure distribution for the actual experimental model by ‘selecting a suitable set of weight factors in which only a small part of the measurements made by electrical-resistance strain gauges must be taken fat some characteristic points in the vicinity of saddle zone. The obtained contact-pressure distribution has ‘Const rosa draton amin fr D auters @ wires D zak Fg. 9. Circumferential streses of Tube 2 been shown in Fig. 7 and the theoretical stress-curves, according to this contact-pressure distribution, are also shown in Figs 8 and 9 and marked with @ to distinguish then, It may be seen from Figs 8 and 9 that in the vicinity of the loading zone, the experimental stress-distribution is quite close to that of the theoretical stresses obtained by the trial-error method. Its mean deviation is about 26%. When the contact radius of the rigid saddle is identical to the tube, larger radiused concentrated loading exists at border edges of the saddle, thus, the above results are rather close to those of Tooth.” Because of the radiused concentrated loadings at the border edges of the saddle a quite large circumferential stress will be developed in the vieinity of the border edges of the saddle. Comparing with the case having clearance contact, the peak circumferential stress in the168 ‘Shen Naije, Zhu Jiao, Lu Wenge vicinity of the border edges of the saddle will increase by 44%, 6 CONCLUSIONS (1) The simple mechanical model designed by the present authors. is convenient for both ‘experimental and theoretical analyses of pressure vessels and piping under saddle loadings. (2) Double Fourier series expansion can be divided into two parts, separately relative to symmetric and antisymmetric functions. In this way various boundary conditions ean be satisfied with enough accuracy in theoretical analysis. (3) The comparison of experimental and theoretical results shows that the trial-error method developed by the present authors can be used to determine the contact-pressure distribu- tion pattern between saddle and tube. REFERENCES 1, Zick, LP Stresses in large horizontal cylindrical fpresture veel on two saddle supports. Welding J. Res Sip 91951) 435-85, 2, Tooth, A. Ss & Motasha, F. A., Radial loading of Shinde vesel throughs sestangulae mgid attachment Td. Pres Ver Ping, 37 (1988) 385-63, 3 Zak, LP. & Carbon, CE, Strain gauge technique Employed in studying propane tank sresses under service editions. Stee, (988) 85-8. . Pe Stress from loa loadings in ylingtcal fressure vessel J. Appl Meck, (1988) 7%6) 805-18. 5. Footh, AS. & Jones, Ne Plstic collapse loads of Spindel pressure vest supported by sid sales. J Siri Anal 173) (1982) 187-38